The Fireplace Company Superior GF 4000 Series User manual

installation
And Operating
Instructions
For Superior
Type
Vented Decorative
Gas Appliance
Natural Gas Model
GF
4000N
I,
LPG Model
GF
4000L
This installation manual will
help, you obtain a safe, effi-
cient, dependable installation
for your gas fireplace.
Please read and understand
these installation instructions
before beginning your installa-
tion.
I DUE TO HIGHTEMPERATURES.
THE APPLIANCE SHOULD BE
LOCATED OUT OF TRAFFIC
AND AWAY FROM FURNITURE
- -
1 AND DRAPERIES.
DO NOT PLACECLOTHING OR
OTHER FLAMMABLE MATERIAL
ON OR NEAR THE APPLIANCE.
SERIES FIREPLACESARE
DECORATIVE GAS
APPLIANCES. DO NOT BURN
WOOD OR OTHER
MATERIALS INTHESE
Do not attempt to modify or
alter the construction of the
fireplace insert or its com-
ponents. Any modification or
alteration of construction may
void the warranty, certification
and approvals of the unit.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don't touch electrical
switches.
3. Extinguish any open
flame.
4. Immediately call your
gas supplier.
FOR YOUR SAFETY
Do not store or use
gasoline or other flam-
mable vapors or liquids
in the vicinity of this or
any other appliance.
PLEASE RETAIN THIS
MANUAL FOR FUTURE
REFERENCE.
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GENERAL
INFORMATION
This appliance complies with
National Safety Standards
and iscertified by the
American Gas Association.
Installation must conform to
local codes. In the absence of
local codes installation must
conform with the National
Fuel Gas Code, ANSI
2223.1-1984. The appliance,
when installed, must be elec.
trically grounded in accor-
dance with local codes, with
the National Electric Code,
ANSIINFPA NO. 70-1984
Note: lnstallation and repair
shouldbe done bya qualified
service person. The appliance
shouldbe inspected at least
annually by
a professional
service person. More frequent
cleaning maybe required due
to excessive lint from
carpeting, bedding
rnateria1,etc. Itis imperative
that controlcompartment,
burners, and circulating air
passageways
of the appliance
be kept clean.
Providefor adequatecombus-
tion and ventilation.
Provide adequate clearances
around air openings into the
combustion chamber and ade-
quate accessibility clearance
for servicing and proper
operation. Never obstruct the
front opening of the fireplace.
Minimum clearances to com-
bustibles are: Sides
0",
Floor 0", Back 0", Ceil-
ing
46", Vent Surfaces I",
Sidewall 6".
Minimum inlet gas supply
pressure is
5.0 Inches water
column natural gas and
11.0
inches water column LPG, for
the purpose of input adjust-
ment.
Maximum inlet gas supply
pressure is
7.0 inches water
column natural gas and
13.0
inches water column LPG.
Input is 14,000 BTUIHR, for
rear burner and
14,000
BTUIHR, for log burner.
A
'Is" N.P.T. plugged tapping
is provided on the gas control
along side of the outlet to the
main burner, for a test gauge
connection.
The appliance and Its in-
dividual shutoff valve must be
disconnected from the gas
supply piping system during
any pressure testing of that
system at test pressures in
excess of
'12 psig.
This appliance must not be
connected to a chimney flue
serving a separate solid.fuel
burning appliance.
The appliance must be
isolated from the gas supply
piping system by closing its
individual manual shutoff
valve during any pressure
testing of the gas supply pip-
ing system at test pressures
equal to or less than '11 psig.
The
GF.4000 header plate
assembly must be installed
during the rough framing stage
of construction.
The header plate assembly
provides for the connection of
either a type
8-4" vent or the
direct rear vent cap assembly
(Model
DRV). In addition, it
also defines the proper fram-
ing depth required for the
GF-4000 series built-ingas'
fireplace.
The Header Plate Assembly
may be installed against a flat
wall, in a diagonal corner or in
an outside chase enclosure
(Figures
1, 2, and 3).
Interior Enclosure
(Flat
Wall)
Figure 1
Oiadonal
(Corner Wall)
Figure 2
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1-38 ' I
Exterior Chase
Figure 3
Floor Plat1
Figure 4
~ ~~~~
=
iristructions on installation
techniques. Also, check with Important: The Header Plate
local
codes.
Assembly must be centered
Any
UL listed type B-4 inch gas
vent may be used to properly
vent the GF4000 series
fireplace system. Refer to the
Tv~e Ei vent manufacturino
.........
j - I exactiy in the framed opening.
Step ': Secure the Header
Plate Assembly to the header
and the rear plate with
six (6) 8d nails (figure 5).
'b NSTALLATION (Using a
Type B Venting System).
INVENTORY LIST:
1-HeaderPlate Assembiy
1.installation instructions
(Header Plate Assembly)
Step
1: Frame fireplace
enclosure as illustrated in
Figures 2,4,5,or
6.
Note: The framed deplh (20"
for a flat wall, 27" for a cor-
ner) must always be measured
from
a finished surface. If a
wall covering such as drywall
is to be attached to the rear
wall then the
20" must be
measured from the dlywall
surface.
Figure 5
Note: If the appliance is tobe
elevated above floor level, the
rear floor plate will have to be
elevated the same distance as
the front floor plate (refer to
Figure
6).
Figure 6
Step 3: Route a '12" NPT gas
line 2'1je" above the floor plate
and 1551s"from the center line
of the framed opening as
shown in Figure
7. The end of
the gas line must be
4"
behind the face of the rough
framing (Figure 7.)
~rdnl Floor Plate
Figure 7
I I
NOTE DIAGRAMS 6 ILLUSTRATIONS NOT TO SCALE
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Step 4: Fasten a 2'12'' x 4"
electrical junction box below
the header, 8"from the right
side of the opening (Refer to
Figure
8)
Figure 8
Step 7: Install the remainder
of the type
B vent. Minimum
height of vent must be
9'121
Note: Refer to vent
manufacturers installation
instructions for variations of
venting techniques.
The pre-installation steps for
the Type
B vent installation
have now been completed.
The final installation of the
GF-4000Series appliance
should be undertaken after
the interior isin the finishing
stages.
!
Step 5: Route a 3 wire 120V 60
Hz power supply line to the
junction box and ground.
FINAL INSTALLATION AND
CO~~ECTION pROCEDURE
INTRODUCTION
Step
6: Connect a 4" type B
vent to the top collar, located
at the rear Of the header plate
assembly. (Refer Figure ').
INSTALLATION
(Fireplace)
The framed enclosure should
now be completed, the gas line
stubbed in the correct position,
the electrical su~~lvline run to
Type
Gas Vent
I I
Figure 9
Before installing the fireplace
in the prepared opening,
check all components for
damage and content with the
inventory list below.
INVENTORY LIST:
1-fireplace(complete)
2-hood retainers
2-sidetrims
1-bottomtrim
1-hood
1-'12'' flex connector with
shutoff valve
1-installation instructions
1-hardwarekit
Step
1: Secure the two (2)
hood retainers to the under-
side of the header and
against the finished wall sur-
face. Nail from underside us.
~ ~
the junction boxahthe
header plate assembly
fastened to the framing
members.
The finished wall material
should also be fastened to the
framing members. The edges
of the finished wall material
must not extend beyond the
framing members so as to
reduce the opening size need-
ed for the fireplace.
A full
38'/zr' width and 30" height is
required for the fireplace.
The maximum thickness for
any finished wall material is
1 % ". Any finished wall
material that exceeds this
dimens~onwill not allow the
side trim pieces to be
attached to the fireplace.
ing two 8d nails
(Figure
70).
NOTE.DIAGRAMS 8 ILLUSTRA~IONS NOT ro SCUE
Figure 10
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Step 2: Attach '12'' flex con-
nector with shut off valve to
the '12" gas supply stub, using
a wrench and pipejoint com-
pound. Tighten securely
(Figure
7 1)
NOTE: Do not damage or kink
the flex connector.
'12. Gas Stub
Shut 011 Valve
'11- Flex Connector
-
'lure 7I
h
Step 3: Remove the flue collar
clamp from the header plate
assembly by removing the
four (4)
#559 machine screws
(Figure
12). Set this clamp and
the four screws aside for later
attachment.
Flue Collar
,
e '
Header
d
Plate
Collar
Figure 12
Step 4: Position the fireplace
in front of the prepared
enclosure opening. Liftthe
fireplace and reset the rear
portion of the lower front
framing plate. Insert the end
of the flex connection into the
rear hole of the fireplace
(Figure
13).
'h- her Connector
Figure 13
Step 5: Carefully slide the
fireplace back into the framed
cavity until the rear of the
fireplace comes incontact
with the rear header plate
assembly.
NOTE: The fireplace must be
centeredin the opening so that
a proper connection can be
made to the headerplate
collar.
Step
6: Reattach the flue collar
clamp, that was previously set
aside, to the rear flue collar
clamp with the four
(4) #I0 -24
X % " machine screws. The
flue collar on the fireplace
must be centered inthe
clamp to effect a gas tight
connection. (Figure
14).
NOTE DLAGRAMS 6 ILLUSlRATlONS NOT TOSC4LE
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GAS LINE CONNECTION
Step
7: Carefully bend and
shape the flex gas connector
SO that a connection can be
made to the adapter mounted
on the gas valve. Caution
should be exercised so as to
not kink the gas connector line
(Figure
15).
Figure 16 illustrates the posi-
tion of the shut off valve
in the
closedposition.
Step
9: Attach the shielded
cable, containing the black,
white and green wires to the
pre-wired junction box. Secure
the wires with the appropriate
wirenuts. Attach coverplate
to
the junction box
(Figure
17).
Ground Shielded Cable
Wire From Fireplace
ELECTRICAL HOOKUP
Step
8: CAUTION-. before
making the electrical connec-
tion, make certain that the
main power supply is
disconnected.
Connector
Figure 15
Figure 17
1 FINISH TRIM AND
HOOD ATTACHMENT
Step
10: The two side trim
I pieces and the bottom trim
piece must be assembled
before attaching to the
fireplace. (Refer to Figure
18
for the methodof assembly).
Figure 18
Step 11: Place the assembled
trim pieces around the sides
and bottom of the fireplace.
Position the side flanges
under the four side trim re-
tainers,
(2 per side). Align up-
per slots, located in side
trims, with holes in the side
of
the GF-4000 and insert the
two screws. Secure the two
I screws with the two wing nuts
so as not to bind the side
trim. Push the side until the
trim pieces fit tight against
the finished wall surface.'
Step
12: Center hnod over the
two hood retainers, that were
mounted to the wall in Step
1.
Slide hood down until the hood
resets on too of the f~re~lace
(Figure 19)
Figure 19
Stepl3: Open the two brass
screen panels
and remove the
glass from the appliance by
removing the two
(2) wing
nuts and upper retaining
bracket(Figure
20). Hold glass
in place while removing re-
taining bracket.
Carefully lift glass up to clear
lower brackets and remove
glass. Save the
2 wing nuts
and upper retaining bracket
for later re-installation of
glass.
L (&
NOIF DIAGRAMS 8 iliUSrRATiONS NOT TO SCALE
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Remove and discard the ship-
ping material holding the logs
in place. Save logs for later
replacement. Handle logs with
care.
Figure 20
CAUTION: DO NOT SUBJECT
,-EDGES OF GLASS TO
IPACT. "STRIKING THE
~ ~ ~. ~. -. .~~~... . . .-
-DGE OFTHIS SAFETY
-
'\d GLASS, OR ROUGH
HANDLING
MAY CAUSE
BREAKAGE".
Step 14: Placethe long log in
the lower front bracket and the
shorter log in the upper rear
bracket. Handle the logs with
care. The logs are constructed
of a new lightweight ceramic
fiber and are subject to damage
if mishandled.
Specifications
LL
-- - --
36'1,' -
. .
TOP
- 22'1.' - - - 22'1."
-- 36',," - ~ -,
-13"- I ,lam --- 13" -
I :,
- !
LL -
r 1
LL. , :
2" - C-
Front
I
- . 16'1."- 4
Lell Side
Right Side
Figure 21
Step 15: Replace the glass
panel, upper retaining bracket
and the two
(2) wing nuts by
reversing the procedure
outlined in Step
13 DO NOT
OVER TIGHTEN WING NUTS.
Close Brass Screens.
OPERATION
-70 operate the appliance refer
> the lighting instructions for
your model. To determine
whlch model you have, refer
@ lo;he silver approval label on
the right side (inside) of the
appliance behind the black
mesh.
Figure 22
....
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Specifications
TW
5'1."
-. -. - -
Front -&,fiq-.-
Hood Side
Figure 23
Bottom Trim
Figure
24
[L a
-- 5' - 22--*- -- 5. -
~elt Front Righl
Side Side
Side Trims
Figure
25
Electronic
Ignition
Models
Natural Gas
j"
I
-1 -
Fmnl
Header Plate
Assembly
Figure
26
Additionally, the gas controls
provided with your appliance
will be either Robertshaw
brand or Honeywell brand. To
determine which type ofcon-
trols are included inyour unit,
look for the identifying marks
on
thc controls thcrnselves.
Alternatively, the lighting
instructions for your ap-
pliance are also located on
the white label located on the
control tray behind access
door. These instructions will
indicate either Robertshaw or
Honeywell controls.
Your appliance control system
is a low voltage
(24 volt) type.
It consists of a pllot burner, a
combination gas control, elec-
tronic ignitor, limit switch, fan
switch, and onloff switch.
To obtain proper operation, it
is imperative that the pilot
and main burner flame
characteristics are steady, not
lifting or floating, and be blue
in color (see Figures
27 and
28 ).Approximately the top ).' ! &
of the pilot thermocouple
should be engulfed in the
pilot flame
(see Figures 31
and 34).
Light Orangs Tip \
,Blue Cone
Nstursl Gas Burner
Typical Healer
(Rear) Burner
Figure 2 7
Blue Cons
,
LPG Gas Burner
Proper Burner Flame Characteristics
Figure 28
NOTE DIAGRAMS liLUSTIlATlONSNOT TO SCALE
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OPERATING
GUIDELINES
AND MAINTENANCE
INSTRUCTIONS
1. Upon completing your gas
line connection, a small
amount of air will be
in the
lines. When first lighting the
appliance, it will take a few
minutes for the lines to purge
themselves of this air. Once
the purging is complete, the
pilot and burners will light
and operate as indicated in
the instruction manual.
Subsequent lightings of the
appliance will not require
such purging.
Note:
LP system may go into
"lockout". System will have to
-+e reset. See Step 8, page 70.
\k
L. When lit for the first time,
the appliance will emit a
slight odor for an hour or two.
This is due to the "curing" of
the logs and "burn-in" of in-
ternal paints and lubricants
used in the manufacturing
process. To minimize this one
time odor, light both burners
inthe appliance and leave in
the "Hi" position for at least
two hours. Additionally, you
may wish to open a few win.
dows to ventilate the room in
which the appliance is
located. Again, this is a "one
time" burn-in procedure and
is not uncommon among gas
fired appliances.
3. The appliance is equipped
with a fan assembly to force
heated air into the room. The
fan operates automatically via
a temperature sensing fan
-.switch. Typically, there will be
1 delay of a few minutes
'& aefore the fan begins running
afler lighting the appliance.
Similarly, the fan may run a
few minutes after the ap-
pliance isturned off.
4. When lighting the ap-
pliance, the inside of the
glass may fog up. This will
burn off after a few minutes
of operation.
5. The inner firebox of the ap-
pliance is manufactured of
reflective stainless steel to
reflect and enhance the
flames of the front log set.
However, the placement of
the logs in relation to the
front burner will greatly affect
the size and burn pattern of
the flames. You may find it
necessary to adjust the posi-
tion of the logs to enhance
the flame pattern. If:so, repeat
Steps
13, 14, and 15 (found
under the installation pro-
cedure on page
7) until
satisfactory flame pattern is
achieved. Caution: the logs
can get very hot.handle only
when cool. Additonally, ad.
justing the air shutter can
also impact the flame size.
The air shutter for the front
burner is located on the right
side of the control tray behind
the access door.
(Do not burn the appliance
without the glass front in
place).
6. Clean glass (never when
hot) and appliance outer cas.
ing with damp cloth. Never
use abrasive cleaners. The
casing and trim is finished in
heat resistant baked enamel
and should
not be refinished
with wall paint.
7. Keep control compartment,
.logs, burners and area sur-
rounding the logs clean by
vacuuming or brushing at
least twice a year.
8. Always turn off gas to pilot
belore cleaning. tor
relighting, refer to lighting
instructions.
9. The appliance and the ven.
ling system should be in.
spected beforeuse or at least
annualy by a qualified field
service person.
10. Always keep the appliance
area clear and free from com.
bustible materials, gasoline
and other flammable vapors
and liquids.
11. Never obstruct the flow of
combustion and ventilation
air. Keep the front of the ap-
pliance clear of all obstacles
and materials.
CAUTION: IFAPPLIANCE
SCREEN OR GLASS IS
REMOVED FOR SERVICING,
THEY MUST BE REPLACED
~. . - .. - - -
PRIOR TO OPERATING THE
APPLIANCE. SCREEN MUST
BE FIXED INTHE CLOSED
POSITION WHEN OPERATING
THE APPLIANCE.
ADULTS SHOULD BE
ALERTED TO THE
HAZARDS OF HIGH SUR-
FACE TEMPERATURE AND
AVOID BURNS OR
CLOTHING IGNITION.
YOUNG CHILDREN
SHOULD BE CAREFULLY
SUPERVISEDWHEN THEY
ARE IN SAME ROOM AS
THE APPLIANCE.
MAINTENANCE
IMPORTANT: Turn offgas and
electrical power before servic-
ing appliance. It is recorn-
mended that a competent ser-
viceman perform these check
ups at the beginning of each
heating season.
NOTE: DIAGRAMS 6 ILLUSTRATIONS NOT TO SCALE
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In order to properiy clean the
burners, heating element and
pilot assemblies, the ap-
pliance will have to be partial-
ly disassembled to gain ac-
cess to these components.
For Access
To Front Burner
Proceed As Follows:
1. Open both screen panels
and remove upper retaining
bracket and glass pane as
outlined in Step
13 on page 6
(Figure 20 and 36).
2. Remove the two logs and log
holder from the innercasing
assembly.
3. Remove screw securing
front burner and remove.
4. Replace all components by
reversing above procedure.
For Access To Pilots, Rear
Burner And Bottom Section Of
Heating Element:
1. Remove lower access door
assembly
(2 screws per side).
2. Disconnect gas supply to
rear of appliance.
3. On the GF4000 Series,
remove red and black wires
from the ignition control
Module (item
23 Figure36).
Remove control tray panel
assembly from appliance by
pulling forward carefully.
Cleaning Burners
Clean all foreign materials
from top of burners and from
bottom panel below burners.
Check to make sure that
burner orifices are clean.
Visually inspect pilot. Brush
or blow away any dust an lint
accumulations.
If pilot orifice
is plugged, disassembly may
be required to remove any
foreign material from orifice
or tubing. When appliance is
put back in service check
pilot fiame patterns with
Figure
29.
Heating Element Cleaning
With control tray panel
assembly removed, the lower-
portion of the heating element
isnow accessible for clean-
ing. A flashlight and small
mirror will be necessary to in-
spect the lower inside portion
ofthe heating element.
Carefully insert a clean cloth
into the bottom opening of
the heating element and
dislodge as much dirt, soot
and other foreign material on-
to the bottom of the appliance
and then vacum clean.
Note: To reinstallall items
removedin the foregoing
maintenance oulline, reverse
the removal procedure to ade-
quately secure each item or
assembly to the appliance.
WARRANTY1
REGISTRATION CARD
Your Gas Fireplace iscovered
by a one year limited warran-
ty. You will find a copy of the
warranty in this manual. Also,
an Owner's Registration Card
is provided.
Please read the warranty to
be familiar with its valuable
coverage and file it with
others you save for future
reference. Also complete and
mail registration card.
TROUBLE SHOOTING
With proper installation and
maintenance,your new Gas
Fireplace should provide
years of trouble-free service.
If
you do experience a problem,
trouble shooting guides are
provided in this manual.
These guides will assist you
or a qualified service person
in the diagnosis of problems
and the corrective action to
be taken.
REPLACEMENT PARTS
Contact the factory for ques-
tions concerning prices and
policies covering replacement
parts. Parts will be shipped at
prevailing prices. Normally,
all parts can be ordered
through your Superior
distributor or dealer.
c
d
When ordering repair parts,
always give the following in-
formation:
1. The model number of the
appliance.
2. The part number.
3. The description of the part.
4. The installation date of the
appliance.
If you have any questions or
problems, do not hesitate to
contact:
SUPERIOR FIREPLACE
COMPANY
Special Services Coordinator
4325 Artesia Avenue
Fullerton, CA
92633
7141521.7302
NOrE DIAGRAMS 6 ILLUSTRATIONS NOT TO SCALE
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::: .:-'!:':L.!::.: Installation And Operating-Instructions
. + ......... .r... ......... .. ... - .. .- . . . ....
End View - Pilot and
Burner
Flame
Figure 29
LIGHTING INSTRUCTIONS
(HONEYWELL
ELECTRONIC SYSTEM
-
ALTERNATE)
Superior GF4000 Series
-Models GF4000N. And GF4000L
~ightingInstructions:
1. Turn onloff (rocker)switch
to "OFF".
2. Turn rear burner knob to
"OFF".
3. Turn gas valve knob to
"OFF" and wait
5 minutes.
4. Turn gas valve knob "ON".
5. Turn rear burner knob to
"ON".
6. Turn onloff (rocker) switch
to "ON".
7. Pilot will automatically light
and burner or burners will
light.
8. (LPG only) if burners are
not lit within approximately
1% minutes, system will
lockout and it will be
necessary to repeat steps
1
thru 7.
'A Shutdown Instructions:
B~
1. The burners may be turned
off for temporary sttuatlons by
turning the onloff (rocker)
switch to "OFF".
NOIE: DIAGRAMS 6 ILLUSTRATIONS NOT TOSCALE
Honeywell - Electronic
- LOW Voltage Mu11 Be R~Iaced. It Must Be
Replscsd Wilh Type AWM tOS*C
18 Gauge Wire Or Equlralent.
EXCBPI Llmll Wlrss Murl Be
125'C.
2 Motor 1s lrnpedanee Overload
Protected
WIRING DIAGRAM -
ELECTRONIC SYSTEM
HONEYWELL
9
.I
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2. For complete shutdown
turn onloff (rocker) switch,rear
burner and gas valve knobs to
"OFF".
LIGHTING INSTRUCTlONS
(ROBERTSHAW
ELECTRONIC SYSTEM)
Superior GF4000 Series
Models GF4000N, And GF4000L
Lighting Instructions:
1. Turn onloff (rockerJswitch
to "OFF".
I
I
2. Turn rear burner knob to
"OFF".
I
5. Turn rear burner knob to
"ON".
I
-
6. Turn onloff (rocker) switch
to "ON".
I
3. Turn gas valve knob to
"OFF" and wait
5 minutes.
4. Turn gas valve knob "ON".
7. Pilot vtill automatically
light and burner or burners
will light in approximately
1 to
30 seconds.
8. (LPG only) if burners are
not lit within approximately
1-1 '12 minutes, system will
lockout and it will be
necessary to turn onloff
(rocker) switch to "OFF", wait
10 seconds and turn onloff
(rocker) switch to "ON".
I Shutdown Instructions:
I
1. The burners may be turned
Off for temporary situations by
turning the onloff(rocker)
switch to "OFF".
Gas Valve Knob
I/,
Flame Sen
PIIO~ Adjustment cap Electrode
Gas Valve
Robertshaw . Eleclronlc
(SP715. Natural) Proper Pllot Flame
lmplngement
Figure 33 (~~735. LP) Figure 34
9 Q
10
-
I Legend Notes: I
2. For complete shutdown
turn onlotf (rocker) switch,rear
burner and gas valve knobs to
"OFF".
Wlrlng Olagram .
Robertshaw Eleclronlc
System
NOTE DIAGRAMS d ILLUSTRATIONS NOT TO SCALE
.... .
Figure 35
0 .,.-- <-,,*
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:,.; .... , : ' Installation And Operating lnstruct~ons
.'+A~L.&~ ..-.. ..-.\ .... i.,- ...... L... . .....- : ...... ............. ......... - ..
TROUBLE SHOOTING
THE INTERMITTENT GAS
PILOT ELECTRONIC SYSTEMS
ROBERTSHAW
SP715, AND SP735
SP715 SP735
GF4000 Series. Model GF4000N GF4000L
Gas Only
{ LPG
Only
N0le:Belore trouble shoofrng lhe lnlerrn,lrent pilot Syslern be sure rhal the exlernalgas shut 011
Valve ison. the gas conlroi valve knob is inthe "ON''posil,on; the manualgas valve is inthe
,,ON" or "H," posilion, the "OFFION" swilch 1s "ON" and!he power supply is on. To assure
Resel(Model SP735 onlyl turn "OFFION" swrlch 011 for 10 seconds. lhen turn back on.
I
NOTE DIAGRAMS 6 lLLUSTRAr!ONS NOT TO SCALE
SYMPTOM
b
1
POSSIBLE CAUSES
1. No Spark
NoPilot Gas
2. Spark but no pilot
gas (no solenoid
valve click)
-
3. Have ignition spark
solenoid valve "click"
but no pilot gas.
CORRECTIVEACTION
A. Low voltage lrans
former
(24 V.AC) or
limit switch
defective.
8. "OFFION"
switch defective
C. Ignition control
unil defective
A. Ignition control
unit defective
8. Gas valve defective
A. Gas supply to
pilot restricted.
Check for
24 volts at the low voltage terminals of the
transformer. If no voltage, turn off electric power to
appliance. Remove one wire from limit switch and check for
continuity across both terminals. Nocontinuity
- replace
limit switch. With a good limit switch back inthe circuit and
the electric power turned on
- if no voltage, replace
transformer. Note: Belore replacing the lranslorrner or limit
swilch, check wiring for loose connections or broken wires
andrepair as needed. With voltage at transformer and still
no spark or solenoid vaive 'click', proceed to step
"8".
Note: Turn 011 eleclricalpower loheater before
replacing lirnil swifch or iranslorrner.
Check for 24 volts across terminals "TH" (black wire) and
"TR (red wire). if there is no voltage present then replace
"OFFION" switch. Note: Before replacing "OFFION" swilch
besure to check wiring for loose connections or broken
wires andrepair as needed. Recheck for voltage between
"TH" and "TR". If voltage is present al"TH" and "TR" and
still no spark or solenoid valve "Click", proceed to step "C".
II you read 24 volts at terminals "TR" and "TH" replace
the ignition control unit.
Check tor
24 volts at terminals of bluewire (PV) and white
Wire (MVIPV) connected to ignition control unit. if no voltage
is present, replace ignition control unit. If OK proceed to
step
"6".
Check for 24 volts at blue wire and orange wire
terminals connected to gas vaive. ~fOK. replace gas valve,
if
no voltage, check wire lor continuity, replace if necessary.
Check andlor adjust pilot flame
- may be too low.
(See Figure
34.)
Pilot line or orifice plugged. clean. Or
replace if necessary.
fire-parts.com

TROUBLE SHOOTING - ROBERTSHAW SP715 AND SP735 (CONT)
I
(solenold cllck)
I
delect~ve
but ptlot does not
Ignht
SYMPTOM
I
careful not to touch any metal parts; d~sconnectthe
electrode wire ("IGN") at the ignition Control. Connect one
end of a lurnoer wire to the metal blade of a small driver.
I
POSSIBLE CAUSES CORRECTIVE ACTION
4 Pilot Gas
1 A. Ignition control
1
Removewire at "TR" terminal at tne ignitioncontrol, being
1
.. ....
5. Pilot burning but main
burners will not
come on.
Note: Wait at leas1
90
Seconds after pilol
before doing
check out for possible
causes~
6. Pilot burns for a
few seconds, then
goes out, after a
few seconds it
relights and goes
out again. Main
burners do not lighl.
7. Burners come
"ON" but
go "OFF"
Intermittently.
B Broken or shorted
electrode assembly.
:
C. Sparking, but not at
Proper locatron
A. Low pilot flameor
unproper alignment
of flame sensor in
'lame.
8. Burner orificeis)
C. Gas Valve delective.
D. Delecl~vemanual gas
valve lor healer or
manual gas valve for
gas logs.
A. Gas valve defective.
8. Ignition control unit
detective.
A. Low pilot flame or
flame sensor not
correctly positioned.
B. Defective limit switch.
..--r. -.,ro~..r.
Positionendof metal blade aDprox. 1W" from "IGN"
terminal. Reconnect "TIT terminal. Sparking should occur
between screwdriver blade and "IGN" terminal.
If no sparking occurs, the Ignition Control must be repiaced.
IfOK. proceed lostep "B".
Check the pilot and electrode assembly for proper electrode
gap (3132" to
118") or any possible shorting of eiectrode to
surrounding metal surfaces. Make sure the spark ignitor and
electrode connections to the ignition control are tight. The
ignition conlrol and pilot. burner must both be chasis
ground.
If there is still no spark, the pilot and electrode
assembly must be replaced. (See Figure 34.)
Electrode tip needs to be realigned for correct location. 118''
gap between electrode tip and pilot hood is desired.
(See Figure
32.)
Pilot andFlame Sensor mustbe properly aligned so that !he
pilot flame umpinges !he top 'h" of the llame sensor. The
flame sensor must bepushedail the way into fhe pilot
bracket^ Adjust pilot flame if necessary. See Figure
-
Check for 24 volts at valve operator terminal "TR" and "TH".
II There is vollage check main burner orifices for stoppage
.clean or replace. IfOK, proceed lostep "C".
-
Main valve operator is defectiveand gas valve must be
replaced.
If gas valve checksOK. proceed to step "D".
Replace approprtate manual gas valve.
Check for
24 volfs at blue wire andorange wire terminals
connected to gas valve, if present replace gas valve.
Check continuity of wires for a broken wire or a loose
connection.
If OK, replace ignition control unit.
Adjust pilot flame andlor check location of flame sensor
(See Figure
34/,
Ifburners go offin less than 5 minutes lrom room term.
perature slarr. replace llrnll swlrcn.
Note: Turn off eleclricalpower to heater before replacing
lmi! swrrch.
I Isrrmarrnus mnr r0SCALE
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,.....,., . , -: ..,: .;
.... :;.:rc:*i... .. ., . . .a:...i..:- !. . .:.;:'.. /nsta//atjon ,And Operating/nstructions
4.r . . . .. ..... ,; ..- . . .. , . . .--..>.. . . ,. .. . . . .
.. ..
-. - .*...,, . . .,....*....-
TROUBLE SHOOTING
2. Have igntionspark
but no pilot gas flow.
S86A AND S86G HONEYWELL ELECTRONIC SYSTEMS
GF4000 Series. Model GF4000N Natural
Gas Only
I
GF4OW [ :KG
Only
Note: Before trouble shooting the intermittentpilot system besure that the external gas
shut otf valve is on, the gas control valve knob is in the "ON" posll~on, both manualgas
valves
are in the "ON" or "HI"posilion, the "OFFION" switch is "0N"and the power cord
from the appliance is plugged in.
-,
.,%-&
C. S66 control module
fuse blownor defec.
live unit.
I
A. S86 control module
defective.
SYMPTOM
1. Noignition spark at
electrode and no pilot
gas flow.
B. "OFFION" switch
B. Gas valve defective.
Turn "OFFION" switch on. Check voltage across terminals
no voltage present. replace "OFFION" switch. Note: netore
replacing switch be sure locheck wiring for loose connec-
tions or broken wires andrepair as needed. Recheck for volt-
age between 25V and25V (biack andred wires).
If voltage is
present at 25V and 25V and still no spark or gas flow at pilot,
Oroceed tosteo "C".
POSSIBLECAUSES
System in lock-out
(reset model S86G only).
A. Low voltage trans.
former (24V-AC)or
limit switch defective.
defective. 25V and 25V (blackwires). on S86 control module. If there is
I I
~ ~
. -
Check for voltage between terminals TH-W and MVlPV on
S86 control module: if novoltage is present check fuse for
continuity - replace fuse if open. With a good fuse in place
and still no voltage - replace $86 control module.
CORRECTIVE ACTION
When safety lock.out occurs, the system will remain in lock-
out until it is reset. To reset the SffiG, lurn the ONiOFFswitch
to "OFF" position, wait 30 seconds and then turn on. If still
no soark, proceed to step
"A".
iurn off electric power to appliance. Remove one wire from
limit switch and check for continuity across bothterminals.
No continuity - replace limit switch. With a good limit switch
back inthe circuit and the electric Power turned on, check for
24 volts at the low voltage terminals of the transformer.
If no
voltage, replace transformer. Note: Before replacingthe trans.
lormer orlimit switch, check wiring for loose connections or
broken wires andrepair as needed With voltage at trans-
former andstill no spark or pilot gas flow, proceed tostep
"6". Note: Turn 011electricalpower loheater before replacing
limit switch or transformer.
Check for voltaCe between PV and MVIPV on
586 cont,ol
modulc If no vo lage 1s Drescnt, replace S86 conlrol mod.!le
I vostaqa IS present. procccc to steo B'
~p
Check for voltage at terminals TH-TR and TR of gas valve. A
no.voltage indicates a broken wire - repair or replace. if
voltage is present, butpilotgas does not flow, check the
follow in^:
.
(a) Pilot adjustment on gas valve too low. (See Figure 31.)
(b) Pilot tine or orlfice for stoppage. Clean or replace if
necessary.
If (a) and (b) are OK, replace defective gas valve.
- I
NOTE. DIAGRAUS & ILLIIS~~A~IONS Nor ro SCALE
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TROUBLE SHOOTING - HONEYWELL S86A AND S86G (CONT)
I SYMPTOM ( POSSIBLE CAUSES I
CORRECTIVEACTION
I
3. Have pilot gas but no
Spark ignition.
4. Pilot burning but
matn burners will not
come on.
A. Delective spark igni.
tton clrcuit or defec.
t~ve 586 control
moduie.
1. Turn off gas valve knob to prevent flow of gas to burner
during the test.
2. D~sconnectignilion cable at S86 stud terminal to isolate
circuit from the pilot burner igniter-sensor. Prepare short
jumper lead, using heavily insulated wire such as ignition
cable.
3. Touch one end ofjumper firmly to S86 ground terminal
(GND). (Do not disconnect existing ground lead.) Move free
end siow.y towards stud terminal toestabiish spark, then
Puil Slowly away from stud - noting the length of gap at
which arcing discontinues.
CAUTION
DO not allow fingers to touch either Stripped end of jumper
Or Stud terminal. This is a very high voltage circuit and elec-
trical shock can result.
4. An arc length ol 'I, in. (3.2 mm) or more indicates satisfac-
tory vollaae output. If no arc Can beestabiished or maxi.
mu~mgapjs less than '1. in. (3.2 mm). and power to 586
input terminals was proved. replace the S86. Then re-open
gas valve knob and repeat perlormance check. (See Fig-
ure
31).
8. Defectiveignition The ignitioncable must not be in contact with metal surlace.
cable. Connections to stud terminals in
586 control module and on
igniter.sensor must be clean and light. Loose connections
may not conduct a fiame current even though ignition spark is
satisfactory. Electricalcontinuity of cable should be checked.
Replace if defective.
C. Check grounding
A common ground is required lor pilot burner ignlter-sensor
defective pilot mounting bracket, pilol burner head, and
GND terminal of
burners, igniter.
S86A. If ground is poor or erratic, safety shutdown may occur
sensor. occasionally even though operation is normal at time of
check-out. Therefore, if nuisance shutdowns have been
reported, be sure locheck the grounding precautions speci-
fied. Eiectr~calground connections at pilot burner, igniter.
sensor and 586 must be clean and tight. If leadwire is dam.
aged or deteriorated, use only No.
14 to 16 gauge, moislure-
resistant, thermoplastic insulated wire with 105'C (221 'F)
minimum rating as replacement. Note: 11 groundcircuit or
path is incomplete. the S86 system control will allow 1 rrial
lorignition before going intosalety lockout. Excessive temp.
erature Of ceramic flame rod insulator will permit electrical
leakage to ground. Examine llame rodand mounting bracket,
andcorrect
if bent out of position. Replace piiot burner
igniter-sensor if insulator is cracked. Visually inspect the pilot
burner igniter-sensor spark gap - it Is factory adjusted to
'I, in. Ifsetting is changed, carelully adjust the angled tip of
the ground electrode only (See Figure 31)
A. Defective S86 con- Check for voltage across MV-MVIPVterminals of
SB6; if no
trol module. voltage
- replace S86. if voltage is presenl, proceed to
Step "El".
8. Defective gas control. Check eleclrical connections between
S86 and gas control; if
OK, replace defective gas control.
-
C. Drfcrtiro rnonual
Replorr oppropriulx. ri,un~uml rtllrc.
healer valve or
manual gas log valve.
NOTE. DIAGRAMS & ILLUSTRATIONSNOr TO SCALE
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.. .
' .%..' .... - ..,.. .. ..:
>*A& ,,= . ;#. . :. . ......., .: ;.:,A> ... ;..!.. -: -.---lnstalla ti on.^ nd Operating Instructions .
.A L.L%. ~rlL;:,~. .-ri:..-- , .... . . . -.-. . . . .. ,.-. : . u. ....A. .-. . . ... . ...-.,
TROUBLE SHOOTING - HONEYWELL S86A AND S86G (CONT)
SYMPTOM
5. Burners are on but go
Off intermtttentiy.
POSSIBLE CAUSES
A. Bad grounding.
6 Switch is "OFF" but
main burners will
not shut off.
CORRECTIVE ACTION
Check ground wire; if poor or erratic, shut down may occur
occasionally even if operation is norrnai at times. Replace or
repair when necessary. If OK, proceed to step "6".
8. Defective ignition
cable.
C. Defective
S86 con.
trol module.
A. Defective "OFFION"
Check operation of switch; if OK, proceed to step "8".
I
Check continuity of ignition cable. Replace where necessary.
If
A and B check OK. proceed to step "C".
Replace $86 control module.
I
8. Defective S86 con.
I
~e'move MV wire from S86 control module; if main burners
trol module. go of1
- replace 586: if not - proceed to step "C".
I
I
C. Defectivegas control. Replace gas control.
I
NOTE- DIAGRAMS 6 ILLUSTRATIONS NOT TO SCALE
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REPLACEMENT PARTS LIST
NOTE: DIAGRAMS 6 llLUSrRAiiONS NOT TO SCALE
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YOTE DIAGRAMS 6 ILLUSTRllltONS NOT 10 SCALE
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